Audit Project

Background

Objectives: To develop and implement Quality Audit within The XYZ

Company

Impact: Effective execution of our requirements through the consistent

execution of quality audits throughout manufacturing

Assumptions: The Quality of our products and processes is a critical component of

the XYZ Company
Compliance to our performance requirements will deliver products
meeting our customer and consumers needs
Audit Project

DMADV Storyboard
Audit Project
D M A D V

Auditing Project – Objective

To develop and implement processes for Quality
Audits of:

➢ All facilities and operations on an annual basis

➢ Suppliers – Major Product Suppliers

Auditing Project – Opportunity Statement

Monitoring and refining our quality assurance processes are critical elements to
maintaining the quality standards of our products as expected by our customers and
consumers.

There is an opportunity to achieve greater consistency in our governance

responsibilities through an audit program addressing the basics of the
manufacturing processes.
Audit Project D M A D V

Preliminary Project Objective:

By January 1, 2005, To develop and implement processes for:
➢ Quality audits of Manufacturing facilities
➢ Environmental and Occupational Health and Safety Audits for manufacturing
facilities
 Audit Project D M A D V
Audit Program –Process Macro Flow
Processes

Req./
New Product Distributio Customer
Core Planning Marketing Production Logistics Sales
Contract
Introduction n Service

Communicate
Business Develop Execute Evaluate
Level 1 Environmental Business
Plans Plans Performance
Data Plans

Determine Execute Report

Secure
Level 2 Audit Audit Audit
Resources
Needs Plan Performance
Audit Project
D M A D V
Audit Level 2 Process: Project Scope
Auditors BU/QD Operating Division Supplier
Schedule

Identify Facilities

Schedule Audits

Collect information and

Prepare

protocols

Complete Logistics

Conduct on-site evaluation

Conduct

including audit close-out

Confirm findings

Issue Audit Reports to

Report

Facility and Division

Issue Audit Summaries

Develop and submit CAP

CAP

Review CAP Execute CAP

Audit Close-out: Confirming the status of the corrective actions

Project Scope taken against the findings of previous audits.
Audit Project
D M A D V
Audit Project – Interview Questions
1. For our team to get a common understanding, please tell us
how you interpret the term “Quality Auditing”?
2. What do you see as the attributes of a successful Quality Identified
Audit program? key attributes
of the program
3. What are the top 3 attributes in order of importance?
4. How would you measure whether a Quality Audit program
meets your expectations on these top 3 attributes?

5. What are your top 3 issues related to Manufactured Quality in

your organization today?
6. Do you see a Quality Audit program helping to resolve these Identified needs
arising from current
issues? challenges
7. If so, how do you see a Quality Audit program helping to
resolve these issues?
8. What information should a Quality Audit program generate for Identified
your organization? informational needs
9. How will this information be used within your organization? and attributes

10. Is there anything else you would like to share with us? “Catch all”
Audit Project
DMA D V

Audit Project – VOC Analysis

➢ Extracted solutions, issues and needs from interviews
➢ 253 need statements transcribed to Post-it notes
➢ Post-it notes color coded by customer segment
➢ Top needs from each customer highlighted
➢ Needs affinitized and sorted using tree diagrams

All customers needs and priorities were similar

Audit Project
DMA D V

Audit Program – Project Track

Tracks Criteria

Gap to
Design Project Discovery Process
Cost Be
Method Size Potential Knowledge
Closed
Small
PMIS small least least highest
moderate

medium moderate
QFD moderate moderate moderate
large large

medium high
Benchmarking high low large
large moderate

QFD (Quality Function Deployment) Track selected

for current project
Audit Project
DMA D V

Audit Project – New Process Objective

To develop and implement a program for Quality

Audits of all Manufacturing facilities and
operations on an annual basis that:
✓ Is reliable
✓ Audits the right things in the right places
✓ Has actionable outputs
Audit Project
DMA D V
Audit Project – Design Ideas
CTQ Design Ideas
Clearly identify where the ➢ In-depth standardized audit modular protocols for systems and compliance
current and potential risks and ➢ Determine audit schedule, type, content and team appropriate for the auditee in
problems collaboration with local BU/Division
Independent Audits ➢ Internal validation process
➢ Use external auditors only
➢ Interdivisional audit teams
Locally Relevant ➢ Incorporation of Division Quality representative in audit team
➢ Audit expertise at BU level to implement and adopt locally
➢ Audit budget is owned at BU level to enable local initiative and adoption
➢ Linked to ISO certification where appropriate
Fair audits ➢ Auditor certification
Verification of completeness of ➢ System for reporting status of findings and corrective actions
Corrective Action ➢ Corrective action escalation procedure
Consistent audits ➢ Decision criteria and process for consistent ratings of individual findings and overall
facility performance
Externally accepted audits ➢ Audit program certified by recognized 3rd party - Mechanism for benchmarking against
other companies to establish competitive advantage

Complete Communication ➢ Audit reporting roll-up process

Audit Project D M A D V

Audit Program – QFD

Hows (Design Requirements)

recognized 3rd party to ISO 19011

Global audit program certified by
&

Decision criteria and process for

forin systems

consistent ratings of individual

process for BOD & Executive

& audit team
appropriate for the auditee in
Hows (Design Requirements)

Global audit reporting roll-up

& audit team audit

findings and overall facility

recognized 3rd party to ISO 19011
Global audit program certified by
modular protocols for systems &

Decision criteria and process for

TCCC Certified auditors

implement global audit & adopt

Audit expertise at SBU level to
collaboration with local
of individual

process for BOD & Executive

standardised

Global audit reporting roll-up

In-depth standardised audit

Use External Auditors only

the auditee

findings and overall facility

protocols
TCCC Certified auditors

collaboration with local

audit

SBU/division

performance
ratings
compliance
audit

Determine
modularfor
SBU/division

performance
In-depth
appropriate
compliance

Comm.
Rating

Determine

consistent

Comm.
Rating

locally
Needs (Whats)
Needs (Whats)
Clearly Identifying current and potential risk
Clearly Identifying current and potential risk
and problems
and problems 48 489 9 9 99 9 9 9 9 3 9
Independent
Independent Audits
Audits 39 39 1 1 9 9 9
TheGlobal
The Global Program
Program is locally
is locally relevant 36
relevant 363 3 9 9 9 1
Fair
FairAudits
Audits 30 309 9 1 13 9 3 9 9 9 1 1
Consistent Audits 24 9 9 3 9 9 1
Consistent Audits
Verification of completeness of corrective
24 9 9 3 9 9
Verification of completeness of corrective
action 21 9 9 1 9
action accepted audits
Externally 21 213 9 1 9 1 3 39
Complete
Externally communication
accepted audits 16 219 3 9 13 3 9 3 1
Importance 1422
Complete communication 16 9 1071 987
9 966
3 900
3 765 514 504
9
Importance 1422 1071 987 966 900 765

How Much January 2003 - 100 % of 25 - 30 80% of time match An accuracy rate of All elements of ISO Provide bi-monthly
100% lead auditors Compliance audit type to 100% for critical 19011 will be reports for BOD
are iso lead modules by January auditee; 100% findings and 80% incorporated into meetings; provide
assessor certified; 1, 2004;100% of the match of audit team accuracy for non- the Global Audit monthly reports to
50% of auditors 15 System modules on process critical findings and Program design by Exec. Com.,Quality
certified to TCCC
Our by June 1, 2004 knowledge; In 2004 overall plant ratings January, 2004. Division and SBU
certified auditor at least 50% of for each audit by heads by February
program audits conducted December 2003 5, 2004
requirements by with fully certified
end of 2004 auditors; 2005 on
(transition). 80% 80% of audits
thereafter as steady conducted with fully
state in system. certified auditors
Audit Project D M A D V

Audit Project – Trade-offs

“Inclusion of Division QA
Top 6 design in audit team” and
elements have no “Convertible Rating
conflicts and are System” conflict with
synergistic other design elements

Potential
synergies and
conflicts between
design ideas
identified
 Audit Project D M A D V
Audit Program – FMEA

Occurrenc

Occurrenc
Detection

Detection
Severity

Severity
Potential
Cause(s) of Current

RPN

RPN
Design Requirement Potential Failure Mode Potential Effect(s) of Failure Failure Controls Recommended Actions

e
Decision criteria and process Incorrect individual findings Over estimation of current 8 Auditor does not 7 10 560 Auditor calibration and training. 8 4 4 128
for consistent ratings of leading to incorrect overall performance leading to false follow process Also, include evidence in
individual findings and overall facility performance rating sense of security and/or mis- working papers that process
facility performance representation of risk & Under was followed. Incoporate
estimation of current review of audit ratings prior to
performance leading to unfair closing meeting.
audits
Determine audit & audit team Inability to capture local ideas / Local levels start performing 6 Lost or 7 10 420 Create a procedure for 6 4 5 120
appropriate for the auditee in request that could be Routine for considering the
audit activities for local issues
mishandled reviewing, sharing learnings
collaboration with local
SBU/division
globalized incorporation of local needs into Audit
and the GAP is unable to
detect local risks.
requests across geographies, and for
validation and tracking of
program solutions with originator within
an agreed timeframe.
Determine audit & audit team Inability to capture local ideas / Local levels start performing 6 Variaton in 6 10 360 Routine for considering the 6 4 1 24
appropriate for the auditee in request that could be audit activities for local issues requests incorporation of local needs
collaboration with local globalized and the GAP is unable to into global audit program (and
SBU/division detect local risks. TCCQS) that includes criteria
for review and evaluation
against TCCC standards and
applicability for globalization.

TCCC Certified auditors Insufficient number of auditors Insufficient resources to meet 8 Transfer of 4 10 320 Develop and apply auditor 8 1 1 8
certified audit objectives Division auditors selection criteria during
who are not transition. Use auditor pool
capable across SBU's while building
SBU capability.Identify multiple
external certification bodies in
design phase.
TCCC Certified auditors Mix of Internal and External
Insufficient number of auditors Insufficient resources to meet
8 Division auditors auditors
4 10 320 Use auditor pool across SBU's 8 4 1 32
certified audit objectives not available for while building SBU
enables annualtransfer
audits of all capability.Identify multiple
external certification bodies in
manufacturing operations design phase.

Top design requirements tested for failure and countermeasures incorporated in design
 Audit Project D M A D V

Audit planning
Audit Program – Process Flow
designed in Report
Determine Execute
accordance Secure Audit
Level Audit Audit
with ISO2 19011 Resources Performance
Needs Plan

Establish Identify Audit Identify Audit

Level 3 Schedule Audits
Current Status Type Team Required

•Identify number of •Determine audit type Select the audit team Develop audit schedule:
plants to be audited required based on facility based on: ▪ Schedule systems audits based
and location maturity on auditee’s readiness and auditor
• Qualification
•Establish maturity of •Determine additional availability
• Right process knowledge
facility and rank auditing needs (obtained ▪ Firm scheduling of compliance
operations based on by use of the collaborative • Location of auditor
audits (prioritized based on risk
potential risk. (Based routine established in the • Language ability profile)
IT Enablers: on Division GAP) • Availability Draft Schedule indicates:
• Searchable assessment against •Determine the preferred • Lead Auditor
established criteria) ▪ Availability of auditee
Auditor and audit timing from the
Divisions ▪ Duration and type of audit
Operation
▪ Timing of audit & team who will
Databases
conduct audit
• Scheduling
Confirmation of schedule
Software
Communication of final schedule

How Much:
80% of time match audit type to auditee; 100% match of audit team on process knowledge; In 2004 at least 50% of audits
conducted with fully certified auditors; 2005 onwards 80% of audits conducted with fully certified auditors

Firm scheduling routines to have the right team at the right location
conducting the right audit
 Audit Project D M A D V
Selection,
training and Audit Program – Process Flow
evaluation
of auditors Determine Execute Report
Secure Audit
consistent
Level 2 with Audit Audit
Resources Performance
ISO-19011 Needs Plan

Certification
Level 3 Selection Training Certification
Maintenance
Select using criteria for: Train auditors in: Certify auditors Certification Periodic re-training and
• Personal Attributes • Audit principles criteria evaluation
• Education • Audit execution
• Related experience • ISO Lead Assessor
• Process Technologies
• Business Processes
• Quality Management
System (ISO-9000)
• Laws and regulations

How much: How much: How much: How much:

By 31 January, 2004 • 80% of auditors trained by • 80% of auditors and 100% Maintain steady state of
• 80 % of internal auditors end of June 2004; of lead auditors certified 80% of auditors and 100%
recruited/transitioned • 100% of auditors certified • Certification criteria by 31 of lead auditors certified
• 100% of external audit to ISO Lead Assessor by December 2004
service providers identified 31 January 2005

Auditor Certification Program - Internal and external auditors have the

right skills and competences
Audit Project D M A D V
Audit Program – Process Flow
Determine Execute Report
Secure Audit
Level 2 Audit Audit
Resources Performance
Needs Plan Audit execution
designed to meet
ISO-19011
guidelines
Level 3 Plan Plant Audit Perform Plant Audit

IT Enabler: Standardized protocol Standardized modules to

• Electronic module for planning, evaluate compliance of Includes
Protocol execution and reporting of processes and systems Decision
Distribution individual audit outcomes during individual audits criteria and
process for
consistent
How Much: ratings.
• 100% of 25-30 Compliance modules completed
by January 1, 2004
• 100% of 14 Systems modules completed by Sub-Team with geographic
June 1, 2004 representation, to compile, review
and standardize modules.
• 100% of Manufacturing Operations audited by
31 December, 2004

In-depth protocols and decision criteria deliver consistent and fair audits
 Audit Project D M A D V
Audit Program – Process Flow Audit reporting
activities
Determine Execute Report designed to
Secure Audit meet ISO-19011
Level 2 Audit Audit
Resources Performance
Needs Plan

Communicate Detailed Summarize Communicate

Level 3
Audit Findings Audit Data Summarized Information
• Detailed Audit report issued to • Gather, analyze and trend data to • Incorporate reporting of audit
Auditee that identifies critical and create a summary report that information into established
systemic risks includes identification of high risk management routines for Quality
• Auditee uses report information to issues, status of corrective action, performance at the BU level.
drive program improvement successful practices and Information can be used to drive
learnings. resource allocation at the BU
• Formalized communication of high and Division level.
risk findings to appropriate • Audit summary to provide
IT Enabler: comparative data of Division / BU • Audit summary provided to
management levels.
• Searchable performance against our BOD. Information will be used as
Audit report performance. input to resource allocation, and
Database greater understanding of the
risks in the organization.

How Much:
Provide bi-monthly reports for BOD meetings; provide monthly reports to Executive Committee,
Quality Division and BU/Vision heads by February 5, 2004

Actionable audit information available - Auditee to BOD

 Audit Project
D M A D V

Audit Program – Detailed Design Ideas

Detailed design ideas related to the process flow generated through:
➢ High level design review with extended team
➢ Surveys Quality Managers)

➢ Idea generation within the Core Team

QUALITY AND TECHNICAL Audit SURVEY
As you are aw are, a team under the sponsorship of Jim Pow er is w orking to design a Quality Audit program for implementation beginning January 2004. The immediate
focus is the program design for audits of Manufacturing Operations.
Early on in the project, SBU heads, Division Presidents and other senior leaders w ere surveyed. Their expectations for the program are:
It is reliable
Audits the right things in the right places

The program design requirements to meet these high level needs are:
Certified auditors
Match audit type and audit team appropriate for the auditee’s facility status, in collaboration w ith local BU/Division
Standardized, modular, protocols and w ork aids for Systems and Compliance audits
Decision criteria and process for consistent ratings of individual findings and overall facility performance
Audit program certified by recognized third party to ISO 19011
Combination of external/internal audit teams
Audit Project
D M A D V
Audit Project - Determine Audit Needs
QFD #1
High Level
Hows (Design Requirements) Design

recognized 3rd party to ISO 19011

Global audit program certified by
modular protocols for systems &
Elem ents

Decision criteria and process for

consistent ratings of individual

process for BOD & Executive

Determine audit & audit team
appropriate for the auditee in

Global audit reporting roll-up

In-depth standardized audit

findings and overall facility

TCCC Certified auditors

collaboration with local

SBU/division

performance
compliance

Comm.
Rating

Needs (Whats)
Clearly Identifying current and potential risk
and problems 48 9 9 9 9 9 Detailed
Independent Audits 39 1 9
The Global Program is locally relevant
Fair Audits
36
30
3
9 1
9
3 9 9
Design
Options
QFD #2
Consistent Audits 24 9 9 3 9 9
Verification of completeness of corrective
action 21 9 9 1 9
Externally accepted audits 21 3 1 3
Complete communication 16 9 9 3 3 9
Importance 1422 1071 987 966 900 765

Options
AUDIT TYPE TEAM SELECTION SCHEDULING

Division QA Manager
Quality Indicator only

Lead Auditor Selects

Previous Audit result

Determined by Audit

Scheudling Process
Div QA Mgr Selects
Hub Audit Manager
Determined using
TCCQS Maturity
continiuum only
CTQs

Determined by

Determined by

Determined by

Determined by

Decentralised
Select Team

Centralised
Scheduling
Manager

Auditee
Weight

Team

Team
Needs (Whats)

High Level TCCC Certified auditors

In-depth standardised audit modular protocols
1422
1071 Preliminary Flowchart
Design for systems & compliance
Determine audit & audit team appropriate for the 987 3 1 3 1 3 3 9 3 1 9 1
auditee in collaboration with local SBU/division
Elem ents
Decision criteria and process for consistent 966
ratings of individual findings and overall facility
performance
Global audit program certified by recognized 3rd 900 9 9 1 3 3
party to ISO 19011
Global audit reporting roll-up process for BOD & 765
Executive Committee
Importance 2961 987 2961 987 2961 2961 16983 11061 1887 11583 3687

Final Flowchart Error Proofing Productivity Analysis Value-Added Analysis

PRODUCTIVITY ANALYSIS VALUE CATEGORY
Critical Risk Flow Process O O STEP P R I M E D O T S Actions STEP VA BVA NVA ACTION
D D 1 Update of EMS with new plant information X Quarterly review and update plant information on EMS 1 Update of EMS with new plant information X
PVP Hub Q.A. Audit Group Lead Auditor Division Auditee S Potential Causes C Current Controls Actions Recommended Resp. Actions Taken S C 2 Determine number of plants to be audited (EMS) 2 X
E E Determine number of plants to be audited (EMS)
ID of critical/high E C E C 3 Request information on plant maturity, risk and audit timing 3 Request information on plant maturity, risk and audit timing X
risk (1)
T T 4 Evaluate every plant against agreed criteria (DIVISION) 4 Evaluate every plant against agreed criteria (DIVISION) X
Communicate Discussion and V What causes the Key U What are the existing What are the actions for reducing the What are the V U 5 Prioritize based on risk and audit timing (DIVISION) 5 Prioritize based on risk and audit timing (DIVISION) X
finding to auditee
(2)
confirmation of
evidence (3) E R E R 6 Comunicate prioritized plant list to audit group (DIVISION) Ask for required information in advance and frequent follow up. 6 Comunicate prioritized plant list to audit group (DIVISION) X
E Input to go wrong? R controls and procedures occurrence of the cause, or improving completed actions E R X
7 Collect prioritized list from divisions X
C P C P 7 Collect prioritized list from divisions
Confirmation of
No
R R (inspection and test) that detection? taken with the R R 8 Any new process identified in the prioritized list? 8 Any new process identified in the prioritized list? X
finding (4)
T N T N 9 Request information regarding new process YES (10), NO(12)
Yes
Continue audit
(6)
I E prevent either the cause recalculated I E 9 Request information regarding new process X
I I 10 Provide information regarding new process
10 Provide information regarding new process X
Telephonic
discussion
Confirm with
audit manager T N or the Failure Mode? RPN? T N 11 Development and inclusion of the new module X Quarterly survey with Division to identify new processes.
11 Development and inclusion of the new module X
with auditor
(7)
(5)
O O 12 Update prioritized list
Y C Y C 13 Compare mandays required with mandays available
12 Update prioritized list X Perform updating of EMS each quarter and detec new processes
N N
No
Agree
(8) 13 Compare mandays required with mandays available X
Yes
Continue audit based on
audit manager comment
E E 14 Are sufficient auditors available within SBU? X X Identify and prepare an external pool of auditors 14 Are sufficient auditors available within SBU? X
Telephonic
discussion Confirm with (13) 15 Are there auditors available in other SBU´that can be used? X Get access to information on auditors in other SBU´s 15 Are there auditors available in other SBU´that can be used? X
with audit
manager (10)
Hub Q.A. (9)
Did not provide the 16 Re-evaluate prioritized list to focus on risk priority X Ensure there are sufficient trained auditors available with the required skills 16 Re-evaluate prioritized list to focus on risk priority X Define sufficient number of auditors, based on process knowledge, language skill,
Establish routines to quarterly for divisions to review GAP location, leading. Reduce number of audits based on risk evaluation
Agree
No
Inform auditor 10 information or update the 4 no current controls 10 400
current status against current EMS content
10 2 5 100 17 Do auditors have required process knowledge? X Ensure there are sufficient trained auditors available with the required skills
Yes
(11) (12)

EMS Mngr 18 Do auditors have required language skill? X Ensure there are sufficient trained auditors available with the required skills
17 Do auditors have required process knowledge? X
18 Do auditors have required language skill? X
Telephonic
19 Is location of auditors suitable for conducting audits? X Ensure there are sufficient trained auditors available with the required skills in yours
Confirmation
with audit
discussion with
division to get a
Discussion with
bottler & Define a procedure for rigorous planning. Use auditor SBU
19 Is location of auditors suitable for conducting audits? X
manager (14) plan for action
preparation of
20 Can audit be re-scheduled? 20 Can audit be re-scheduled? X
(15)
CAP (16)

Planning of resources pool across SBU's while building SBU capability. GAP 21 Is there a lead auditor available? X Ensure there are sufficient trained auditors available with the required skills in yours 21 Is there a lead auditor available? X
No 9
ineffective
4 no current controls 10 360 Identify multiple external certification bodies in design 9 2 4 72 22 Allocate resources to the prioritized list SBU 22 Allocate resources to the prioritized list X
Agree with Forward plan by Mngr 23 Prepare/Review Draft Schedule X Note: Minimize this loop with more active involvement with the Divisons in the early 23 Prepare/Review Draft Schedule X Note: Minimize this loop with more active involvement with the Divisons in the early
content of CAP
(18)
email to audit
manager (17) phase. stage of the scheduling process.
stage of the scheduling process.
Yes
24 Communicate Draft Schedule to Divisions 24 Communicate Draft Schedule to Divisions X
Voice mail to SBU Inform Hub 25 Agree with draft schedule? (DIVISION) 25 Agree with draft schedule? (DIVISION) X Note: Minimize this loop with more active involvement with the Divisons in the early
Q.A.and copy
Pres. Copy PVP, Div.
Pres, SBU QA, SBU division
26 Communicate proposed changes (DIVISION) X Note: Minimize this loop with more active involvement with the Divisons in the early stage of the scheduling process.
Tech, Div Tech technical
detailing critical status director (19)
stage of the scheduling process. Alternately commit the Division to respond within 26 Communicate proposed changes (DIVISION) X Note: Minimize this loop with more active involvement with the Divisons in the early
(20)
Process for updating is GAP an agreed timeframe or the schedule would be accepted as it is. stage of the scheduling process.
8
not followed
4 no current controls 10 320 Audit the updating process at a local level 8 2 4 64 27 Are changes feasible? X
Mngr 27 Are changes feasible? 28 Communicate to Divison that changes are not possible X Note: Minimize this loop with more active involvement with the Divisons in the early
28 Communicate to Divison that changes are not possible stage of the scheduling process.
29 Prepare final schedule 29 Prepare final schedule X
30 Communicate final schedule 30 Communicate final schedule X

Detailed design options selected, flowcharted and measures identified

Audit Project
D M A D V
Audit Program – Features of Electronic Management System

Document Management
Audit program, management of procedures and modules, incorporating:
• Document creation • Document revision
• Document review • Document approval
• Document distribution • Document control
• Document archiving
(Above done with electronic workflow)

Recordkeeping Auditor Capability

Plant maturity and operational data • Personnel information:
Audit reports • Education
• Field for high risk, corrective action • Work Experience
status and successful practices • Auditor training
• Status of corrective action receipt • Auditor experience
• Audit schedule status • Auditor qualifications (incl. Auditor
• Search of reports by: Certification status)
• Risk • Auditor internal/external
• BU • Languages, nationality, location
• Division • Course and skill profiles
• Filter/search capability

This functionality is available with current solutions and/or off-the-shelf software

Audit Project
D M A D V
Individual Ratings - Revalidation Exercise

Conclusions:
➢ Improved consistency in applying the definitions
➢ Auditors did not have a good understanding of the findings
used (and/or lack of context or different context)
➢ Most auditors did well with the audit format

Next Steps:
➢ Incorporate above into development of ongoing Auditor
Training and Calibration exercises (already built into
Auditor Development and Certification)
 Audit Project Process Management Control System DM A D V
Process Name: Primary Customer Customer’s CTQs: Clearly ID Current & Outcome Indicators (Ys):
Audit of Process: Plant Potential Risk & Problems Y1= % of Reportable Incidents That Were Preventable
Management Fair Audits Y2=% of Survey Scores Indicating Dissatisfaction

Outcome Upstream
Misc.
Process Map Indicators Indicators Capturing Data
Information
(Ys) (Xs)
Mfg. Audit Needs
Determine Global -Name -Name -Indicator Formula
Indicator “Physical” Who -Procedures
-Numerator & -Numerator & When to Recovery
Chart Item to Performs
Hub Audit Group SBU/Divison Bottler
Manufacturer Denominator Denominator Check Action -Abbreviations
Type Check Check
- Specification or Description -Comments
Determine Current Status and Audit Type

1
Evaluate Plants using
Previous Audit Performance X1.1 = % of P Chart Audit Plan Weekly Hub Audit HUB Mgr The team must
and Maturity
Audits Mgr adjusts to collectively cover all
2 Scheduled with get a the process
Prioritize Risk & Timing
of Audit
incomplete qualified knowledge and local
knowledge on audit team knowledge required.
3
team prior to All team members
Identify Audit Type (# of audit audit must have been
knowledge execution trained in behavioral
4 requirements skills. Each audit will
Do Existing Audit
Modules Cover Content
not met in have 3 defect
Needed ? schedule / total opportunities ( (1)
No
number of audit process knowledge
knowledge required, (2) local
5
Contact TCCQS to requirements knowledge (culture,
Create Module Yes scheduled in 1 language, gov’t, etc.,
wk) (3) behavioral skills.)

6 7
ID Audit Team

Are there Re-Evaluate List

No
Qualified Auditors and Prioritize to
Available Focus on Risk

Yes

8 X1.1
Allocate
Auditors

9 10
Draft Schedule and Agree With
Communicate Schedule ?

11
Schedule Audits

Are Changes No
Feasible

12
No
Adjusted Schedule

13
Communicate
Final Schedule
Yes
Rev # Date Change Log – Describe Revisions By Apppr

1 12/30/03 B. Cappad
Audit Project

Summary

• The Design was completed on schedule and full

scale implementation began January 5, 2005

• Preliminary results indicate all CTQs will be met

• An estimated $2.0 million in cost saving from

improved productivity and global contracting

• Audit process design can be created and

implemented in 4 months